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WIR SCHAFFEN WISSEN – HEUTE FÜR MORGEN
Conformity Assessment Procedure forboth Detectors DMC und CHARM
Dieter Graf :: Techniker für Maschinenbau HF :: Paul Scherrer Institut
DENIM VIII, September 17-19, 2019 in North Bethesda, MD
• Overview of DMC
• Basics for our designWhat exists and what is in operation
• Conformity Assessment ProcedureCourse of actionMaterial inspectionPressure proof test
• Conclusion and Experience
Table of Contents
Seite 2
Orientation about DMC
Seite 3
Picture Archive PSI
Schematic Representation for DMC
Seite 4
Picture from Lukas Keller, PSI
From Instrument Side for DMC, PSI
Old Detector
Solid Angle
New Detector
Solid Angle
Basics for our Design
Seite 5
Picture downloaded from Ansto, Instrument Side «Wombat»
Wand2, Oak Ridge National Laboratory (ORNL) - Picture copied from LANSCE_ND120_Owners_Manual-1
Picture from Karl Zeitelhack, TUM
Difference between Generations
Seite 6
1. Generation 2. Generation
Instrument Wand2 / Wombat DMC / CHARM
Standard ASME AD2000
Vessel Material EN AW-7075EN AW AlZn5.5MgCu
EN AW-5083EN AW AlMg4.5Mn0.7
Elastic Limit 260-470 N/mm2 105-125 N/mm2
Strain to Rupture 2-8% Min. 12%
Flange Material 1.4301 1.4404
Sealings NBR Metallic
Screws Grade 8 (10.9) BUMAX 88 (1.4435)
AD2000 Regulations: specify all basic safety and conformity regulations that must be observedin accordance with the European Pressure Equipment Directive (PED) 2014/68/EU ASME: American Society of Mechanical Engineers, ASME Boiler and Pressure Vessel CodeDatas from « Metall Service Menziken »
Challenge from our side
Mental blockade concerning
Detectors in use and defined design
Prototype in use with certification through ILL
• First calculation for our aluminum alloy and redesign window area
• After Assignment of a mission for supervision and certification for TÜV-CH
• Discussion about influence from AD2000 for the design
Pressure proof 10bar or 7.7bar
Inspection conditions non-destructiv tests
Choose right aluminium alloy EN AW-5083 one and only
Dimension and appropriate material for the screws «A4-70 or A4-80» or «8.8 or 10.9»
Selection for the metal sealings coating material, quantity of screws, forces or after all «rubber»
Conformity Assessment Procedure
Seite 7
Redesign CAD CATIA
Conformity Assessment Procedure
Seite 8
Original Window Window-Modifications
Calculation Analysis for Pressure of 7bar
Seite 9
According to AD2000:
Minimal elastic limit needed 125N/mm2
by 14% elongation in x,y,z-direction
• According to AD2000
1.43 x PB (Liquid) oder 1.1 x PB (Gas)?
95% from elastic limit (direction ?!)
Conformity Assessment ProcedureDefinition Test Pressure
Seite 10
By 1.43xPB is elastic limit Rp0.2 overrun
for EN AW-5083 sheetsElastic Limits
Rp0.2Tensile strenght
RmThickness
Raw material = forged ring
Table: DIN EN 485-2:2009-01
Elongation
%
• Material properties to test in all main direction
• Recalculation
• Material Certification used aluminium alloy
• Basic material free from defects
• US-test according to DIN EN 10288-3; Classe 4
• Dye Penetration Process DIN 10228-2 in the window
As Consequence of the calculation and AD2000
Seite 11
2 US-tests = 2 Results for defects
IMBACH ≠ ALCA
Position for the defects is not clear
Cause of defects is high
no guaranty by new order
Cast process unknown
Risk by purchaser
Risk is up to the Purchaser
Seite 12
Dye Penetration Process DIN 10228-2
Seite 13
Located defects are not correlated with the US test.
Our Interpretation: Cracks from milling
Conformity Assessment ProcedureMaterial-Specific-Values
Seite 14
Test specimen for tensil test and charpy test in all 3 direction
Conformity Assessment ProcedureTensile Test Results
Seite 15
Probe-Kennzeichnung
Strain to Rupture εin %
Tensile StrenghtRmin N/mm2
Elastic Limit Rp0.2
in N/mm2
X3 36.4 302 122Y2 29.8 324 142Z1 17.7 305 134
• Vacuum proof by ALCA
• Pressure test with 10bar in PSI and TUM for electric flanges (still in progress)
• Pressure vessel with blind flanges with 7.7bar proof pressure by PSI
Proof Pressure Process
Seite 16
Test Procedure with Nitrogen
• 0.5bar leak test
• 3.8bar view and sound control
• 7.7bar Endpressure for 30min
Additional
• Measurement the deformation for the
window
• Measurement for the broadening on the side
• Measurement the acoustic emission
Pressure Test
Seite 17
DeformationWindow (mm)
Broadening left(mm)
Broadening right(mm)
DMC 0.64 1.04 0.24CHARM 0.69 0.86 0.35
Material for Screws
Seite 18
Conditions:
Material for screws with very deep Permeability µ < 1.1
Smallest dimension M4 (certificate of exemption)
AD2000 compatibility
Not allowed/ not enough:
Stainless screw A4-80 (AD2000-B8)
Screws with strength class 10.9 or higher (AD2000-W7)
Screws must be more than M6 (AD2000-B7)
Chosen and accredited:
BUMAX A4-88 (> 800N/mm2)Elastic limits
Screw Material
Seite 19
DIN 4762-M5x18-A4-BUMAX88DIN 4762-M4x16-A4-BUMAX88
• All sealings have to be in metal quality from Technetics
Sealings
Seite 20
Photo from Technetics: https://technetics.com/produkte/dichtungslosungen/metalldichtungen/helicoflex/
downloaded
• Dokumentations
- Test results
- Declaration of
conformity
- user manual for
- Gas cleaning
- maintenance and
revision
Open Works
Seite 21
• Team-Work- Person in Charge for DMC
- Design Engineer
- Detector Developer
- Mechanics
- Vacuum engineer
- Pressure Test Responsible
- Materials Science
- Engineer for FEM-Calculation
• TÜV-Switzerland Certification office
from start
• Open Mind for the Certification process
• Communication between- all project involved people
- all Project responsible people
- all suppliers
• Time-consuming
• Standards AD2000 und EN ISO DIN
• Collective Responsibility for Decisions
• Exchange for Experiences and Knowledge
Conclusion and Experience
Seite 22
DIN EN 1591-1Flanges and their joints
Seite 23
Wir schaffen Wissen – heute für morgen
My Thanks goes to
• TÜV SwitzerlandCh. Mikusky
T. Häntzka
• TUMK. Zeitelhack
• ALCA TechnologyM. Cencherle
F. Anselmi
• PSIL. Keller
M. Hiltebrand
M. Mähr
P. Spätig
and a lot more
Seite 24
Wir schaffen Wissen – heute für morgen
Questions?